Installation, early warning method and device of high-drop buffer chute funnel

Abstract

The present application belongs to the technical field of metallurgical equipment, and particularly relates to a kind of installation, early warning method and device of high-drop buffer chute hopper. It comprises the following steps: (1) installing chute hopper: reserving space for installing buffer pad inside the chute hopper, and externally supporting; (2) drop grading: reasonably grading the inner wall of the chute hopper according to the drop of the chute hopper, the gravity of the blocky material being transported; (3) making and installing buffer pad: installing buffer pads in proper positions at each drop grading point of the inner wall of the chute hopper according to the horizontal spiral direction; (4) installing online monitoring system: monitoring and analyzing the actual pressure of the chute hopper sidewall at each buffer pad installation point through online monitoring. The present application solves the problems of material crushing and equipment wear and tear in the process of transporting blocky material with high drop through reasonable grading and buffering, and meets the needs of transporting blocky material with high drop and high efficiency.

Description

Technical Field

[0001] This invention belongs to the field of metallurgical equipment technology, and particularly relates to a method and device for the installation and early warning of a high-drop buffer chute funnel. Background Technology

[0002] With the rapid development of science and technology and the economy, enterprise production is becoming increasingly large-scale and specialized, leading to a growing demand for material conveying with height drops exceeding 10 meters. Due to factors such as the material's own weight, height drops exceeding 10 meters generate significant impact forces, causing material breakage and other adverse consequences during the conveying of lumpy materials. This also greatly increases equipment wear, such as wear on the chute and funnel walls, deformation of the downstream conveyor belt supports, and shortened service life. To address this, most enterprises have implemented two types of improvements to high-drop material handling points: one is to install intermediate belt conveyors, and the other is to replace straight chute funnels with corner chute funnels. The former has higher investment and operating costs and stricter geographical requirements, limiting its widespread adoption; the latter exacerbates funnel wear, leading to frequent material leakage and spillage accidents, and severe material accumulation at corners can easily cause material to detach from the funnel, potentially resulting in major safety accidents.

[0003] According to the search, the high-drop material buffer chute with application number CN202310580207.X and announcement number CN116513694A effectively reduces the impact of high-drop materials on the lower receiving conveyor belt and equipment by setting multiple sets of discharge valve plates inside the chute, thereby reducing dust. This patented technology mainly uses springs behind the valve plates for buffering. If the reserved discharge port between each set of discharge valve plates is too large, it will affect the conveying efficiency; if it is too small, the buffering effect will be poor, making it only suitable for conveying small material flows.

[0004] A search revealed that the high-drop corner chute funnel with patent number 201821032585.5 utilizes movable insert plates to form an impact-resistant working surface, solving the problem of high-drop material conveying. This patented technology is only suitable for conveying small, granular, bulk materials. The high-drop buffer chute funnel provided by this patented technology, through reasonable grading and buffering, can meet the high-drop, high-efficiency conveying requirements of lumpy materials. The high-drop buffer chute funnel provided by this patented technology, through reasonable grading and buffering, balances buffering and conveying needs, meeting the high-drop, high-efficiency conveying requirements of lumpy materials. Summary of the Invention

[0005] The purpose of this invention is to provide an installation and early warning method and device for a high-drop buffer chute funnel, so as to solve the problems existing in the prior art.

[0006] The technical solution adopted by this invention to solve its technical problem is:

[0007] A method for installing and providing early warning of a high-drop buffer chute funnel includes the following steps:

[0008] (1) Install the chute funnel: The chute funnel has a reserved space inside for installing a buffer pad, and external auxiliary support;

[0009] (2) Drop classification: The inner wall of the chute and funnel is divided into equal parts according to the drop of the chute and funnel and the weight of the conveyed blocky material;

[0010] (3) Fabricate and install buffer pads: Install the buffer pads at appropriate positions on the inner wall of the chute funnel at each drop classification point in the horizontal spiral direction.

[0011] (4) Install an online monitoring system: monitor and analyze the actual pressure on the side wall of the chute and funnel at each buffer pad installation location online.

[0012] Furthermore, step (2) drop classification includes drop point analysis, drop gravity analysis, and reasonable equal division;

[0013] Analysis of the material drop point confirms that the initial material drop point is the installation location of the first-stage buffer pad.

[0014] The gravity analysis of the drop is as follows: Based on gravitational acceleration and material buffering requirements, a reasonable number of stages is calculated. The calculation formula is: F = T × 2Vn × g × Ln, where F is the withstandable free-fall impact force, T is an empirical coefficient, Vn is the material conveying speed, and g is the gravitational acceleration, taken as 9.8 m / s². 2 Ln represents the drop between the buffer pad layers;

[0015] The reasonable division involves dividing the inner wall of the chute funnel into equal parts according to a reasonable number of levels, determining the installation levels of the buffer pad, and the calculation formula is: S = L 总 / Ln, where S is the reasonable grading number, and its value is taken as an approximation, and L... 总 The effective vertical drop is Ln, which is the drop between the buffer pad layers.

[0016] Furthermore, the method for making and installing the buffer pad in step (3) is as follows: the length of the upper receiving plate of the buffer pad is the length of one side of the inner wall of the chute funnel, and the width is calculated using the formula: (n×L) 总斜 ) / (S×cosα), where n is an empirical coefficient, ranging from 0.6 to 0.8, α is a preset buffer angle, ranging from 15 to 45°, and L 总斜 S represents the effective length of the inner wall of the chute funnel, and S represents the reasonable number of stages.

[0017] The lower buffer pad of the buffer plate is made of multiple layers of rubber pads, and its length is the length of one side of the inner wall of the chute funnel. The formula for calculating the width of the bottommost rubber pad of the lower buffer pad is: (n×L) 总斜(S×cosα)+installation width, the other rubber pads of the lower buffer pad decrease sequentially from bottom to top to form a preset buffer angle, and are fixed to form a support plate by steel plate and bolts. The support plate is welded and fixed at the angle space between the upper material receiving plate and the inner wall of the chute funnel. The lower buffer pad is supported on the support plate and is in close contact with the upper material receiving plate.

[0018] Furthermore, in step (4), the pressure sensor of the online monitoring system is installed on the outer wall of the chute funnel of each level of buffer pad, and the early warning system is installed on the relevant industrial control microcomputer. The pressure sensor monitors the pressure of each level of buffer pad online. If the pressure exceeds the threshold range, an early warning signal is issued to prompt the personnel on duty to check and handle it.

[0019] Furthermore, the early warning principles of the online monitoring system are as follows:

[0020] If the pressure from fewer than m / 2 pressure sensors exceeds the upper limit threshold and the pressure persists for a duration of t, a warning signal for material accumulation on the x-th level buffer pad will be issued.

[0021] If the pressure from more than m / 2 pressure sensors exceeds the upper limit threshold and the pressure persists for a duration of t, a material overload warning signal will be issued.

[0022] If the pressure from fewer than m / 2 pressure sensors is less than the lower threshold and greater than 1.1 × static pressure, and the duration is t, then a warning signal for wear of the x-th level buffer pad is given.

[0023] If the pressure from more than m / 2 pressure sensors exceeds the upper limit threshold and this condition persists for a duration of t, a warning signal indicating that the material is too small will be issued.

[0024] Where: t is the duration, which can be set and controlled between 30 and 120 seconds; m is the number of pressure sensors; and x is the level where the pressure sensor that exceeds the threshold is located.

[0025] The upper and lower threshold values ​​are determined through actual testing and are empirical values, or:

[0026] The upper limit threshold is determined by the formula: maximum allowable material weight per unit time × sinα × V1, where V1 is an empirical constant for the upper limit, ranging from 1.05 to 1.15.

[0027] The lower limit threshold is determined by the formula: minimum allowable material weight per unit time × sin(α / 2) × V2, where V2 is an empirical constant for the lower limit, ranging from 0.85 to 0.95.

[0028] A high-drop buffer chute funnel includes a chute funnel with several buffer pads spirally arranged from top to bottom inside the chute funnel. Each buffer pad includes an upper receiving plate, a lower buffer pad, and a support plate. The upper receiving plate is hinged to the inner wall of the chute funnel, and the lower buffer pad is located between the upper receiving plate and the chute funnel. The lower buffer pad is supported by a support plate made of steel plate, which is welded to the inner wall of the chute funnel. Pressure sensors are installed on each of the chute funnels where the lower buffer pads are located, and the pressure sensors are all connected to an industrial microelectromechanical system (MEMS).

[0029] The present invention has the following beneficial effects:

[0030] 1. By rationally classifying and buffering, the problems of material breakage and equipment wear in the process of conveying high-drop block materials are solved, thus meeting the demand for high-efficiency conveying of block materials.

[0031] 2. It can monitor the wear and tear of the buffer facilities online, making maintenance convenient and operation highly efficient.

[0032] 3. Low investment, reliable operation, and easy for other manufacturers in the same industry to promote and apply. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of the steps of the present invention.

[0034] Figure 2 This is a schematic diagram of the structure of the present invention.

[0035] The components include: 1. chute funnel; 2. upper receiving plate; 3. lower buffer pad; 4. support plate; and 5. pressure sensor. Detailed Implementation

[0036] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0037] Example 1: This example provides a method for installing and providing early warning of a high-drop buffer chute funnel, including the following steps:

[0038] like Figure 1 As shown, taking the hopper 1 of the 3800 blast furnace trough as an example, the vertical hopper (L) 总斜 =L 总 The drop is 15m, the cross-section is 2.2m long and 2m wide, and the belt speed of the upper and lower processes is 2m / s. The specific implementation of the present invention will be further described below with reference to the accompanying drawings.

[0039] (1) Install chute funnel 1: The chute funnel 1 has a reserved space inside for installing a buffer pad and external auxiliary support.

[0040] The original chute funnel 1 has enough space to reserve for the installation of buffer pads according to the drop level. The external support is provided by tie rods and thickened steel plates to prepare for the installation of buffer pads.

[0041] (2) Drop classification: Based on the drop of the chute hopper 1 and the gravity of the conveyed blocky material, the inner wall of the chute hopper 1 is divided into reasonable equal parts.

[0042] First, the initial drop point of the material conveyed from the previous process into the chute hopper 1 was collected, recorded, and analyzed to determine that the first-stage buffer plate was installed 1.0m-1.8m vertically on the drop side of the inner wall of the chute hopper 1. Second, gravity analysis was performed to measure and determine the effective length L of the inner wall of the chute hopper 1. 总斜 =Vertical effective drop L 总 =15m. Based on gravitational acceleration and material buffering requirements (F≤180N), the reasonable number of stages S is calculated to be 5. The inner wall of chute hopper 1 is divided into five equal parts according to the calculated reasonable number of stages to determine the specific levels at which the buffer pads are installed on the inner wall of chute hopper 1. The relevant calculation formulas are as follows:

[0043] It can withstand the impact force of free fall F=T×2Vn×g×Ln=1.5×2×2×9.8×Ln≤180.

[0044] Based on the above formula, we can calculate that Ln≤180 / (1.5×2×2×9.8)=3.06.

[0045] Reasonable number of grades S = L 总 / Ln=15 / 3.06=4.9≈5.

[0046] (3) Make and install buffer pads: Install the buffer pads in the appropriate positions of each drop classification point on the inner wall of the chute funnel 1 in the horizontal spiral direction.

[0047] The buffer pad mainly consists of an upper receiving plate 2 and a lower buffer pad 3. The upper receiving plate 2 can be made of corrosion-resistant steel plate, and its length is the length of one side of the inner wall of the chute funnel 1, 2.2m on the front and back sides, and 2m on the left and right sides; the width = (n×L) 总斜) / (S×cosα)=(0.7×15) / (5×cos30°)=2.42m, the empirical coefficient n is taken as 0.7, and the preset buffer angle α is taken as 30°. The upper material receiving plate 2 of the first stage is installed vertically downward 0.9m on the front side of the inner wall of the chute funnel 1. The other upper material receiving plates 2 are installed in the same way in the horizontal spiral direction at appropriate positions in each drop classification point on the inner wall of the chute funnel 1. The lower buffer pad 3 is made of multi-layer rubber-like micro-elastic hard material. Its length is the same as the inner wall of the chute funnel 1 on one side, 2.2m on the front and back sides, and 2m on the left and right sides. The bottom rubber pad is 2.45m wide (installation width 0.03m). The other rubber pads decrease in width from bottom to top to form a preset buffer angle. They are fixed together with steel plates and bolts to form a support plate 4. The support plate 4 is welded and fixed in the angle space between the upper material receiving plate 2 and the inner wall of the chute funnel 1. The lower buffer pad 3 is supported on the support plate 4 and is in close contact with the upper material receiving plate 2.

[0048] (4) Install an online monitoring system. Install pressure sensor 5 at an appropriate location on the outer wall of the five-stage buffer plate chute funnel 1. The early warning system is installed on a relevant industrial control microcomputer. The system uses a PLC to extract the pressure of the five-stage buffer plate online. If the pressure exceeds the threshold range, an early warning signal is issued, prompting personnel to check and handle the situation. Based on actual testing, the upper limit threshold is set to 2 MPa, the lower limit to 200 kPa, and the static pressure to 0.2 kPa. Corresponding early warning examples are as follows:

[0049] If the pressure detected by the first and second level pressure sensors 5 is >2MPa and lasts for 60s, a warning signal “material accumulation in the first and second level buffer pads” will be given.

[0050] If the pressure detected by the first, second, and third level pressure sensors 5 is >2MPa and lasts for 60s, a warning signal "material overload" will be given.

[0051] If the pressure detected by the second and third level pressure sensors 5 is <200KPa and >0.2KPa, and lasts for 60s, a warning signal "wear of the second and third level buffer pads" will be given.

[0052] If the pressure detected by the third, fourth, or fifth level pressure sensor 5 is <200KPa and >0.2KPa, and lasts for 60 seconds, a warning signal "material too small" will be issued.

[0053] Actual operation steps:

[0054] 1) Turn on the industrial control computer, confirm that the pressure sensors 5 at each level are intact and the static pressure is normal, then set the upper limit threshold to 2MPa, the lower limit threshold to 200KPa, the static pressure to 0.2KPa, and the allowable duration to 60 seconds.

[0055] 2) The PLC monitors the pressure of each level of buffer pads online. If the pressure exceeds the threshold range, an early warning signal is issued. The personnel on duty will check and deal with the problem in a timely manner according to the early warning prompt until the early warning signal is eliminated.

[0056] Example 2: This example provides a high-drop buffer chute funnel, which is installed and manufactured based on the method of Example 1.

[0057] like Figure 2 As shown, a high-drop buffer chute funnel includes a chute funnel 1. Several buffer pads are spirally arranged from top to bottom inside the chute funnel 1. The buffer pads include an upper receiving plate 2, a lower buffer pad 3, and a support plate 4. The upper receiving plate 2 is hinged to the inner wall of the chute funnel 1. The lower buffer pad 3 is located between the upper receiving plate 2 and the chute funnel 1. The lower buffer pad 3 is supported on the support plate 4 made of steel plate. The support plate 4 is welded to the inner wall of the chute funnel 1. Pressure sensors 5 are installed on the chute funnel 1 where the lower buffer pad 3 is located. The pressure sensors 5 are all electrically connected to the industrial control microelectromechanical system.

[0058] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the concept and scope of the present invention. Various modifications and improvements made to the technical solutions of the present invention by those skilled in the art without departing from the inventive concept should fall within the protection scope of the present invention.

[0059] The technologies, shapes, and structures not described in detail in this invention are all known technologies.

Claims

1. A method for installing and providing early warning of a high-drop buffer chute funnel, characterized in that, Includes the following steps: (1) Install the chute funnel: The chute funnel has a reserved space inside for installing a buffer pad, and external auxiliary support; (2) Drop classification: Based on the drop of the chute and the weight of the conveyed blocky material, the inner wall of the chute and funnel is divided into equal parts. (3) Fabrication and installation of buffer pads: The buffer pads are installed at appropriate positions on the inner wall of the chute funnel at each drop classification point in the horizontal spiral direction. (4) Install an online monitoring system: monitor and analyze the actual pressure on the side wall of the chute funnel at each buffer pad installation location online; The drop classification in step (2) includes drop point analysis, drop gravity analysis, and reasonable equal division; Analysis of the material drop point confirms that the initial material drop point is the installation location of the first-stage buffer pad. The gravity analysis of the drop is as follows: Based on gravitational acceleration and material buffering requirements, a reasonable number of stages is calculated. The calculation formula is: F = T × 2Vn × g × Ln, where F is the withstandable free-fall impact force, T is an empirical coefficient, Vn is the material conveying speed, and g is the gravitational acceleration, taken as 9.8 m / s². 2 Ln represents the drop between the buffer pad layers; The reasonable division involves dividing the inner wall of the chute funnel into equal parts according to a reasonable number of levels, determining the installation levels of the buffer pad, and the calculation formula is: S=L 总 / Ln, where S is the reasonable grading number, and its value is taken as an approximation, and L... 总 The effective vertical drop is Ln, which is the drop between the buffer pad layers. The method for making and installing the buffer pad in step (3) is as follows: the length of the upper receiving plate of the buffer pad is the length of one side of the inner wall of the chute funnel, and the width is calculated using the formula: (n×L) 总斜 ) / (S×cosα), where n is an empirical coefficient, ranging from 0.6 to 0.8, α is a preset buffer angle, ranging from 15 to 45°, L 总斜 S represents the effective length of the inner wall of the chute funnel, and S represents the reasonable number of stages. The lower buffer pad of the buffer plate is made of multiple layers of rubber pads, and its length is the length of one side of the inner wall of the chute funnel. The formula for calculating the width of the bottommost rubber pad of the lower buffer pad is: (n×L) 总斜 (S×cosα) + installation width, the other rubber pads of the lower buffer pad decrease sequentially from bottom to top to form a preset buffer angle, and are fixed to form a support plate by steel plate and bolts. The support plate is welded and fixed at the angle space between the upper material receiving plate and the inner wall of the chute funnel. The lower buffer pad is supported on the support plate and is in close contact with the upper material receiving plate.

2. The installation and early warning method for the high-drop buffer chute funnel according to claim 1, characterized in that, In step (4), the pressure sensor of the online monitoring system is installed on the outer wall of the chute funnel of each level of buffer pad. The early warning system is installed on the relevant industrial control microcomputer. The pressure sensor monitors the pressure of each level of buffer pad online. If the pressure exceeds the threshold range, an early warning signal is issued to prompt the personnel on duty to check and handle it.

3. The installation and early warning method for the high-drop buffer chute funnel according to claim 2, characterized in that, The early warning principles of the online monitoring system are as follows: If the pressure from fewer than m / 2 pressure sensors exceeds the upper limit threshold and the pressure persists for a duration of t, a warning signal for material accumulation on the x-th level buffer pad will be issued. If the pressure from more than m / 2 pressure sensors exceeds the upper limit threshold and the pressure persists for a duration of t, a material overload warning signal will be issued. If the pressure from fewer than m / 2 pressure sensors is less than the lower threshold and greater than 1.1 × static pressure, and the duration is t, then a warning signal for wear of the x-th level buffer pad is given. If the pressure from more than m / 2 pressure sensors exceeds the upper limit threshold and this condition persists for a duration of t, a warning signal indicating that the material is too small will be issued. Where: t is the duration, which can be set and controlled between 30 and 120 seconds; m is the number of pressure sensors; and x is the level where the pressure sensor that exceeds the threshold is located. The upper and lower threshold values ​​are determined through actual testing and are empirical values, or: The upper limit threshold is determined by the formula: maximum allowable material weight per unit time × sinα × V1, where V1 is an empirical constant for the upper limit, ranging from 1.05 to 1.

15. The lower limit threshold is determined by the formula: minimum allowable material weight per unit time × sin(α / 2) × V2, where V2 is an empirical constant for the lower limit, ranging from 0.85 to 0.

95.

4. A high-drop buffer chute funnel according to any one of claims 1-3, characterized in that, The system includes a chute funnel, inside which several buffer pads are spirally arranged from top to bottom. Each buffer pad includes an upper receiving plate, a lower buffer pad, and a support plate. The upper receiving plate is hinged to the inner wall of the chute funnel, and the lower buffer pad is located between the upper receiving plate and the chute funnel. The lower buffer pad is supported by a support plate made of steel plate, which is welded to the inner wall of the chute funnel. Pressure sensors are installed on the chute funnel where the lower buffer pad is located, and the pressure sensors are all connected to an industrial control microelectromechanical system (MEMS).

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